CN1365406A

CN1365406A - Bulkyl sheet and process for producing the same

Info

Publication number: CN1365406A
Application number: CN01800587A
Authority: CN
Inventors: 静野聡仁; 石川贤司; 町井功治; 铃木彦行
Original assignee: Kao Corp
Current assignee: Kao Corp
Priority date: 2000-03-24
Filing date: 2001-02-13
Publication date: 2002-08-21
Anticipated expiration: 2021-02-13
Also published as: HK1046937A1; US20030008108A1; JP2001336052A; MY140461A; AU3226801A; CN100392166C; AU778886B2; US6936333B2; US20050136218A1; ES2425440T3; KR20020033598A; EP1190134B1; WO2001071081A1; EP1190134A1; KR100730880B1; TW572745B; ID30220A; JP3537775B2

Abstract

A bulky sheet comprising a fiber aggregate formed by water needling of a fiber web is disclosed. The bulky sheet has a number of projections and depressions comprising the fiber aggregate. The projections and the depressions is formed both by rearrangement of the constituting fibers of the fiber aggregate by water needling of the fiber aggregate and by the multiple bending manner of the fiber aggregate along the thickness direction thereof. The projections and the depressions retains the shape thereof by themselves.

Description

Bulkyl sheet and preparation method thereof

Technical field

The present invention relates generally to and have a large amount of concavo-convex Bulkyl sheets and preparation method thereof, more particularly, the present invention relates to be suitable for and make for example Bulkyl sheet and preparation method thereof of mouth mask or gauze of cleaning sheet or hygienic articles.

Background technology

The flat 8-158226 of Japanese Patent Application Laid-Open discloses a kind of concavity and convexity Bulkyl sheet, it is by being integral nonwoven fabric that non-thermal contraction fiber and height heat-shrinkable fiber (crimped fibre) are tangled, and heats this nonwoven fabric and form concavo-convex method preparation.Yet the camber of this Bulkyl sheet is quite little.Also have, the layer of being made by crimped fibre becomes more closely knit harder when heating, only can obtain the sheet material that flexibility greatly reduces.In addition, increased manufacturing cost for forming the concavo-convex heat treatment of carrying out.

Inventor of the present invention had proposed a kind of method for preparing Bulkyl sheet in the past, this method comprises the nonwoven fabric that is formed by fibre matting with the mesh sheets enhancing, and forms convex-concave surface (referring to flat 5-25763 of Japanese Patent Application Laid-Open and 5-192285) by the heat shrink mesh sheets.The sheet material that obtains thus is characterised in that its suitable concavity and convexity, soft feel and comfortable sense of touch, but this method needs a heater to shrink mesh sheets.In addition, the concaveconvex shape pattern is decided by the mesh pattern of mesh sheets, and this is because the nonwoven fabric servo-actuated produces concavo-convex in the contraction of mesh perforate.Therefore, the sheet material relief pattern that can form is limited.

The flat 4-327255 of Japanese Patent Application Laid-Open discloses the method that a kind of preparation has the relief pattern nonwoven fabric, this method comprises and fiber assembly is placed on the conveyer belt with raised design and applies High-Pressure Water or hot-air is pressed in it on conveyer belt to following fiber assembly, forms relief pattern entangled fiber simultaneously thus.According to this technology, although can obtain having the nonwoven fabric of arbitrary graphic pattern, this nonwoven fabric is can not be than himself thickness thicker and also do not have a bulking.

The description of invention

The purpose of this invention is to provide a kind of a large amount of concavo-convex Bulkyl sheets that have, the soft sense of touch of this sheet material is comfortable, when when the cleaning sheet, can capture dust or dirt that floor ditch seam or furniture, electrical apparatus product etc. are not difficult to remove with conventional cleaning sheet in the plane surface.

Another object of the present invention provides a kind of method for optimizing for preparing this Bulkyl sheet.

Above-mentioned purpose of the present invention is to be realized by a Bulkyl sheet that contains the fiber assembly that forms by the current needled web, described Bulkyl sheet have in a large number by described fiber assembly constitute concavo-convex, described concavo-convex be to rearrange it by the described fiber assembly of current acupuncture to form fiber and the multiple bend mode that it carries out is formed along the fiber assembly thickness direction, and describedly concavo-convexly self have shape retention.

This purpose also realizes that by the method for optimizing of this Bulkyl sheet of preparation this method comprises the steps:

The current needled web forms a fiber assembly thus with the described fibroreticulate composition fiber that tangles each other,

Described fiber assembly is sent on the composition assembly (patterning member) with a large amount of concavo-convex or a large amount of perforates and

The described fiber assembly of part is projected a large amount of projectioies that form in described depression or the described perforate corresponding to described depression or described perforate,

The thickness of described composition assembly is 5-25mm, or air penetrability is 800-3000cm ³/ (cm ²Sec),

At least satisfy the mode of a following general formula with ENERGY E m and ENERGY E f, ENERGY E m and ENERGY E f be applied to respectively on described fiber web and the described fiber assembly:

200(kJ/kg)＜Em+Ef＜1250(kJ/kg)

Em/10＜Ef＜2Em/3

Wherein, Em is applied on the described fiber web energy that forms described fiber assembly by described current acupuncture, and Ef is applied on the described fiber assembly energy that the part fiber assembly is projected on the described composition assembly.

This purpose also realizes by the Bulkyl sheet that contains the fiber assembly that is formed by current needled web and mesh sheets, described Bulkyl sheet have in a large number by described fiber assembly constitute concavo-convex, the composition fiber of the described fiber assembly that tangles each other by described current acupuncture further tangles with described mesh sheets and/or heat bonding forms one thus, described concavo-convex be to rearrange it by the described fiber assembly of current acupuncture to form fiber and the multiple bend mode that it carries out is formed along the fiber assembly thickness direction, and describedly concavo-convexly self have shape retention.

Form one on the described mesh sheets thus being thermally bonded on the one or both sides of mesh sheets and with described composition pars fibrosa with described fiber assembly is superimposed,

Described fiber assembly is sent on the composition assembly with a large amount of concavo-convex or a large amount of perforates and

200(kJ/kg)＜Em+Ef＜1250(kJ/kg)

Em/10＜Ef＜2Em/3

Brief description of drawings

Fig. 1 is the enlarged perspective of Bulkyl sheet embodiment of the present invention;

Fig. 2 is along the amplification sectional view of A-A line among Fig. 1.

Fig. 3 is the device sketch that can be used to prepare the Bulkyl sheet of Fig. 1.

Fig. 4 (a) is the amplification view of the embodiment of composition assembly 27, Fig. 4 (b) be among Fig. 4 (a) along the sectional view of b-b line, Fig. 4 (c) is along the sectional view of c-c line among Fig. 4 (a).

Fig. 5 (a) is the oblique view of another composition assembly of expression, and Fig. 5 (b) is the sectional view of composition assembly in the presentation graphs 5 (a).

Implement best way of the present invention

Bulky material of the present invention is described the concrete preferred implementation of form with reference to the accompanying drawings.As illustrated in fig. 1 and 2, the fiber assembly 1 that formed by the current needled web of the Bulkyl sheet 10 in this specific embodiment and the mesh sheets 4 of fiber assembly 1 inside are formed.Fiber assembly 1 and mesh sheets 4 form one, and fiber (hereinafter being called " composition fiber ") and the mesh sheets 4 of wherein forming fiber web 1 are to tangle each other by the current acupuncture of describing in detail below.

As illustrated in fig. 1 and 2, Bulkyl sheet 10 has first surface 10a and second surface 10b, and has in a large number from the outstanding projection 2,2 of a side direction opposite side ...In projection 2,2 ... between form depression 3,3 ..., making whole sheet material is concaveconvex shape.

As shown in Figure 1, projection 2,2 ... size is roughly the same, produces a regular pattern, and each has the shape on long and narrow mountain in the plane.At sheet material transversely (among Fig. 1 in X-direction or this embodiment CD direction), the distance of projection between 2 and 2 is approximately 1-10mm, more preferably 1-7mm, vertically (among Fig. 1 in Y direction or this embodiment MD direction), this distance is 4-20mm, more preferably 4-15mm.This projection 2 is the possibility partial continuous in the horizontal of sheet material and/or vertically.The projection of separating with this spacing 2 not only makes the sense of touch of sheet material 10 comfortable, and the cleaning sheet that makes thus removes floor ditch seam or the dust in the plane surface and the relative big foreign matter of capture disintegrating slag for example not admirably.

When Bulkyl sheet was used as cleaning sheet, preferably its two sides had the projection 2 of substantially the same configuration, and promptly shape, size and interval are to have identical performance.Particularly preferably be, the gross area that second surface 10b goes up projection 2 is the 20-100% of the first surface 10a gross area, particularly 35-100%.In the preferred implementation, projection 2 has covered the depression 3 on the second surface on the first surface.In another preferred implementation, the shape of projection 2 shape with depression basically is opposite.

Projection 2 and depression 3 contain fiber assembly, only form by the entanglement of forming fiber in the fiber assembly 1.With the thermoplastic resin fibre is partly heated and pressurize (for example, by cotton ginning) causes that those projectioies that heat bonding forms are different, projection 2 and depression 3 senses of touch are comfortable.When the cleaning sheet, when for example particularly cleaning sheet use on the floor, Bulkyl sheet 10 had the performance of excellence when trap dust, hair, velveteen etc.

The configuration of projection 2 can freely design as mentioned above.On the contrary, the configuration of the Bulkyl sheet of the flat 5-25763 description of above-mentioned Japanese Patent Application Laid-Open (thermal contraction by mesh sheets forms) protrusions is controlled by the mesh pattern of the mesh sheets of limited design freedom.

Because the projection 2 of Bulkyl sheet 10 and depression 3 are to rearrange and tangle again by the current needling action to form fibroplasticly, so they have kept himself shape.Therefore, projection 2 and depression 3 may be caved under load hardly.Because the existence of projection 2 and depression 3, Bulkyl sheet 10 ratios form projection 2 and depression 3 fiber assembly 1 before has bigger apparent thickness.On the other hand, only the projection that forms of the contraction by the mesh sheets described among 5-25763 and the 5-192285 does not have shape retention.Suppose to remove mesh sheets in the Bulkyl sheet from 5-25763 and 5-192285, this projection can not keep its shape, and is easy to subside.When as cleaning sheet, have the projection 2 of good shape retention and the Bulkyl sheet of depression 3 and will clean ditch seam or convex-concave surface and capture disintegrating slag etc. better.When this Bulkyl sheet 10 is used to cleaning device for example during mop, these advantages will be obvious especially.This shape retention is further by improving entanglement and/or the heat bonding of mesh sheets 4 with the composition fiber of fiber assembly 1.

The shape retention of projection 2 can be passed through load 15gf/25cm ²(=59Pa) be the initial apparent thickness and the load 96gf/25cm of sheet material down ²Difference under the (=376Pa) between the apparent thickness of sheet material is assessed, and wherein back one load is the load (being called " varied in thickness " hereinafter) that applies in the simulation cleaning operation.This shape retention is preferably, even still keep the shape of projection 2 and depression 3 under load, and above-mentioned varied in thickness is 1mm or littler, particularly 0.8mm or littler.

Term used herein " rearranges and tangle to form again " and be meant and carries out current acupuncture to forming fiber once more by the slight fiber assembly that tangles of current acupuncture on the composition assembly, make fiber along convex/concave or perforate rearranges or tangle again, composition assembly wherein has a large amount of concavo-convex or a large amount of perforates.

As shown in Figure 2, projection 2 and depression 3 are to carry out multiple bend mode by the thickness direction along fiber assembly 1 to form.The a large amount of bendings that form in the fiber assembly 1 are corresponding to projection 2 and depression 3.Projection 2 and depression 3 form in by fiber assembly 1 fiber rearrange formation in since the composition fiber that fiber causes with respect to the migration of depression in the projection 2 that High-Pressure Water causes be distributed in the inhibition that is subjected to utmost point low degree in the processes that projection 2 and depression 3 form.It is said that the aggravation of forming Fiber Distribution will cause the formation of unfavorable hole in the projection 2.Its leavening structure is strengthened although its Unit Weight of this Bulkyl sheet reduces.On the contrary, the relief pattern because Fiber Distribution in the nonwoven fabric of (use High-Pressure Water changed subsequently the quantity of fiber causes on the thickness direction) generation, the nonwoven fabric of describing among the flat 4-327255 of Japanese Patent Application Laid-Open does not have bending in specification of the present invention.As a result, for this nonwoven fabric, can not obtain high bulkiness.Its in-plane is crossed in multiple bending in the fiber assembly 1, comprises vertically (MD) and/or laterally (CD).Do not have under the situation of Fiber Distribution, the multiple bending of fiber assembly 1 can realize by controlling the energy that following current acupuncture applied.

Flexibility can be assessed by the rate of curving, and its method of testing will be described below.Bulkyl sheet 20 has up to 2-15%, particularly the high rate of curving of 3-15%.

Bulkyl sheet 10 is at density preferred average out to 50-850 on optional position 10cm * 10cm unit are on this side of projection 2 on the side.Under this density of protrusions, more balances that projection 2 and depression 3 distribute, and this Bulkyl sheet 10 is during as cleaning sheet are capturing and the little and bigger foreign matter of clamping for example has more excellent performance in the disintegrating slag.

The long-pending 23-100cm that is preferably of the apparent specific volume of Bulkyl sheet 10 ³/ g, particularly 25-90cm ³/ g, especially 30-80cm ³/ g.Apparent specific volume is long-pending less than 23cm ³During/g, Bulkyl sheet 10 will be difficult to fully comply with consistent come trap dust or foreign matter with the ditch of cleaning material seam or convex-concave surface when being used as cleaning sheet.If the long-pending 100cm that surpasses of apparent specific volume ³/ g, the distance between fiber and the fiber is too big, and perhaps the thickness of fiber assembly is too little, and this may produce difficulty when the clamping foreign matter.

Apparent specific volume is long-pending to be defined as: the merchant that apparent thickness (being defined as follows) obtains divided by the Unit Weight (if used mesh sheets, then not comprising its Unit Weight) of fiber assembly.

Under the simulation load of cleaning operation, the long-pending 18cm that is preferably of the apparent specific volume of Bulkyl sheet ²/ g or bigger, particularly 20cm ²/ g or bigger.The long-pending upper limit of apparent specific volume can be 100cm ²/ g.

As shown in Figure 2, Bulkyl sheet 10 is extremely bulk, and its apparent thickness T (distance between the darkest bottom of first surface 10a top and second surface 10b) is bigger than the thickness t of fiber assembly 1 self.

For guaranteeing that distance enough in the sheet material makes it bulk and is fit to do cleaning sheet, the apparent thickness T of Bulkyl sheet 10 is preferably 1-5mm, more preferably 1.4-4mm.Thickness t by the fiber assembly 1 of the Unit Weight of fiber assembly 1 and processing conditions decision is preferably 0.5-4mm, more preferably 1-3mm.See Fig. 2, height of projection h is preferably 0.2-4mm, more preferably 0.5-4mm.The thickness t of fiber assembly 1 is to pass through 15gf/25cm ²What the tangent plane of observed Bulkyl sheet was measured under the light microscope under the load of (=59Pa).

For prevent to prepare or use in the projection 2 that causes of the elongation of Bulkyl sheet 10 and the distortion of depression 3, this Bulkyl sheet under the sample 30mm 5N of wide place load, its vertically (MD) elongation be 5% or littler, particularly 4% or littler.

The longitudinal tensile strain test is as follows.Along vertically cutting out the wide sample of 30mm perpendicular to Bulkyl sheet.This sample is fixed at tensile test machine jaw place, exposes the sample computational length of 100mm, and longitudinally stretches with the speed of 300mm/min.Read the elongation of TENSILE STRENGTH when being 5N/30mm.Then, with the data that obtain original length 100mm, and then multiply by 100 and obtain this elongation divided by sample.

The fiber assembly 1 and the mesh sheets 4 of Bulkyl sheet 10 will be described below.The fiber assembly 1 of forming Bulkyl sheet 10 is to tangle each other by the current needled web to form the nonwoven fabric that fiber obtains.With compare by heat bonding or the fiber web of forming the bonding formation of fiber, only form fibroplastic fiber assembly 1 and make and form fiber and have the bigger free degree by tangling.As a result, this fiber assembly 1 has for example performance of hair, velveteen or dust of excellent capture foreign matter, and soft.

Say it for example, the composition fiber of fiber assembly 1 comprise the present inventor at first to file US5, those fibers of describing during the 525,397, the 3rd hurdle 3-10 is capable, its relative section is cited for referencial use in this article.The angle of the leavening structure of the unfavorable formation of hole and increase and maintenance fiber assembly 1 from prevent fiber assembly 1, fiber number is that 5 dtexs or littler fiber content are preferably 50% weight or higher, and particularly 3.5 dtexs or littler fiber content are 70% weight or higher.In addition, when as cleaning sheet, the Bulkyl sheet that contains such fiber with such content advantageously captures foreign matter for example hair and dust.The length of the Unit Weight of fiber assembly 1 and composition fiber can be selected according to purposes and processability, the expense etc. of Bulkyl sheet.For example, the cleaning time spent, the unfavorable formation of hole and improve sufficient leavening structure and keep the angle of leavening structure in the Bulkyl sheet 10 from prevent preparation process, the Unit Weight of fiber assembly 1 is preferably 30-100g/m ², preferred 40-70g/m ², the length of forming fiber is preferably 20-100mm, particularly 30-65mm.Fiber assembly can be used in combination the surfactant that improves its surface physical properties and can adsorb dust, perhaps is used in combination the lubricant of giving cleaning lustrous surface.

As mentioned above, the Bulkyl sheet 10 according to embodiment of the present invention contains a mesh sheets 4 in fiber assembly 1 inside.As shown in Figure 1, mesh sheets 4 is resin web of square mesh.This mesh sheets 4 preferably has 0.1-1000cm ³/ (cm ²Sec) air penetrability.As long as air penetrability satisfies above-mentioned scope, just can use other type mesh sheets for example nonwoven fabric, paper and film outside the resin web.The composition fiber of fiber assembly 1 not only tangles between them, and tangles and/or heat bonding with mesh sheets 4, and the result makes Bulkyl sheet 10 improve TENSILE STRENGTH on the whole.The linear diameter of mesh sheets 4 is preferably 50-600 μ m, particularly 100-400 μ m, and width of mesh (distance between the adjacent netting twine) is 2-30mm, particularly 4-20mm.Say it for example, mesh sheets 4 can be by US5, and the material that the 3rd hurdle 39-46 describes in capable in 525,397 is made, and its relevant portion is cited for referencial use in this article.Satisfy requirement of the present invention as long as contain the Bulkyl sheet of this mesh sheets, the material of making this mesh sheets 4 so can be thermal contraction.The mesh sheets of being made by heat-shrinkage material 4 can be heat-treated in preparation Bulkyl sheet process, apparent thickness T that this Bulkyl sheet is had increase and sharper projection.Yet Bulkyl sheet 10 does not carry out the thermal contraction of mesh sheets.In addition, when Bulkyl sheet was heat-treated, its percent thermal shrinkage 140 ℃ of following tests in 3 minutes was preferably 3% or littler.

For the feel of guaranteeing suitable thickness with improve processability, the Unit Weight of Bulkyl sheet 10 is preferably 30-110g/m ², be preferably 40-80g/m ²Enough intensity angle from practicality, Bulkyl sheet 10 preferably is at least 5N, particularly 7N or higher in the fracture strength of the wide sample of 30mm.The fracture strength that is enough to make Bulkyl sheet 10 any direction on its plane be 5N or higher in, preferably, laterally (CD) fracture strength is 5N or higher, this direction is considered to the minimum direction of intensity in the plane.From practical angle, the upper limit of fracture strength can be 20N.

The method of testing of fracture strength is as follows.On the direction vertical, cut out the wide sample of 30mm with the Bulkyl sheet fiber orientation directions.This sample is fixed at the jaw place of tensile test machine, exposes the clamping length of 100mm, and stretches along the speed of the vertical direction of fiber orientation directions with 300mm/min.Read the load that sheet material begins fracture (first peak value in the follow-on test in the chart).

Below will the concrete method for optimizing of describing preparation Bulkyl sheet of the present invention with reference to the above-mentioned Bulkyl sheet of preparation.Below with reference to Fig. 3 and Fig. 4 (a)-4 (b).According to describing step, this method comprises: will go up respectively fiber web 1a and following fiber web 1b superimposed on mesh sheets 4 with below, current needled web 1a and 1b make each form fiber and tangle each other, form fiber assembly thus, composition fiber and the mesh sheets of further tangling simultaneously forms one lamilated body 6 thus, this lamilated body 6 is sent to contains on a large amount of concavo-convex composition assemblies, the part fiber assembly is projected form in the depression in a large number projectioies corresponding to depression.

Fig. 3 represents that one is preferred for realizing that said method prepares the device 20 of Bulkyl sheet 10.This device 20 is divided into superimposed part 20A, entanglement part 20B and composition part 20C.

Superimposed part 20A comprises carding machine 21A and the 21B that is paved into fiber web 1a and 1b respectively, feed respectively fiber web 1a and 1b a pair of feeding roller 22 and 22 and the feeding mesh sheets 4 feeding roller 24.

Entanglement part 20B contains fiber web the support belt 25 and first water jet 26 of an annular.

Composition part 20C contains the composition assembly 27 and second water jet 28 of an annular.Composition assembly 27 rotates in a direction indicated by the arrow.In the back of composition part 20C one conveyer belt 29 is arranged.Consider and give sheet material 10 with enough leavening structures and the efficiency of giving leavening structure, the thickness of composition assembly 27 is preferably 5-25mm, especially 5-15mm.In like manner, the air penetrability of composition assembly is preferably 800-3000cm ³/ (cm ²Sec), more preferably 800-2000cm ³/ (cm ²Sec).

The details table of composition assembly 27 is shown among Fig. 4 (a)-4 (c).Fig. 4 (a) is the amplification view of composition assembly 27.Fig. 4 (b) is the sectional view along Fig. 4 (a) b-b line, and Fig. 4 (c) is the sectional view along Fig. 4 (a) c-c line.

Shown in Fig. 4 (a)-4 (c), composition assembly 27 is made up of straight line 27a and screw line 27b.Say it for example, straight line 27a has circle or elliptic cross-section, is arranged in parallel with a determining deviation each other.Straight line 27a preferred arrangement in one plane.Single screw line 27b is coiled on per two straight line 27a spirally.Every adjacent two screw line 27b have identical coiling direction and coiling pitch.Every screw line 27b is made up of two circular cross-section lines, and diameter is identical, tightly is bonded together side by side to form the cross section of a ∞ shape.Certainly, also can use single line or three lines or more lines.Screw line 27b arranges like this, makes two lines of centres of forming line parallel with straight line 27a always.In addition, form the diameter of every line of single screw line 27b for circular or

oval.Line

27a and 27b are made by metal or synthetic resin.

In the embodiment shown in Fig. 4 (c), from the direction of helical axis, screw line 27b is drawn as ellipse, and its spindle parallel is in the plane that straight line 27a arranges.In addition, when the direction from it, screw line 27b can be drawn as circle or triangle.

Shown in Fig. 4 (b), screw line 27b has a large amount of peak 27d and paddy 27e on basal plane (the plane 27c that straight line 27a forms).In brief, composition assembly 27 has a large amount of projectioies and depression.Term " projection " is meant peak 27d and the peripheral region of representing with symbol 27f thereof, and the part between the two adjacent peak 27d that term " depression " is digit symbol 27g to be represented.

The composition assembly along the Y shown in Fig. 4 (a) to rotation.Between the adjacent straight line 27a apart from a _pDetermined the length of Bulkyl sheet 10 protrusions 2.The coiling pitch b of screw line 27b _pControlled the spacing of Bulkyl sheet 10 protrusions.The cross-sectional width b of screw line 27b _dThe width of expression projection.The minor axis b of the ellipse that the spiral of screw line 27b is represented _h(diameter when spiral has circular cross-section) controlled the apparent thickness of the Bulkyl sheet that obtains.The apparent thickness of the Bulkyl sheet that obtains also depends on ENERGY E m and the Ef that describes below.

The width a of straight line 27a _dWith pitch a _pBe respectively preferred 1-5mm, more preferably 1-3mm, and 4-20mm, more preferably 4-15mm.The width b of screw line 27b _dWith coiling pitch b _pThe preferred 1-10mm of difference, more preferably 1-6mm, and 2-12mm, more preferably 2-7mm.The spiral minor axis b of screw line 27b _hPreferred 3-18mm, more preferably 5-

15mm.Line

27a and 27b satisfy under the prerequisite of these conditions, and composition assembly 27 can make fiber assembly produce enough convex-concave surfaces, to obtain a Bulkyl sheet.

In device 20 superimposed part 20A, feeding roller 22 feedings by separately respectively from the fiber web 1a of each carding machine 21A and 21B and 1b respectively.Mesh sheets 4 is from being placed on unwinding on the roller 23 between carding machine 21A and the 21B, and fiber web 1a and 1b are superimposed on each face of mesh sheets 4 by the feeding roller, form superimposed body 5.

In entanglement part 20B, superimposed body 5 is sent to the fiber web support with on the belt 25, and with the High-Pressure Water acupuncture of penetrating in first water jet 26, at the composition fiber of this fiber web 1a and the 1b formation fiber assembly that tangles each other, simultaneously, these composition fibers also tangle with fiber web 4 and form one deck zoariums 6.For the fiber of forming fiber assembly in the lamilated body 6, the low entanglement is preferred.It is 0.05-2N.m/g that the entanglement degree of fiber assembly preferably makes its entanglement coefficient, particularly 0.2-1.2 N.m/g.Entanglement degree by fiber assembly in the key-course zoarium, so that the entanglement coefficient is above-mentioned scope, this lamilated body can form clearly relief pattern and not make Bulkyl sheet form disadvantageous hole in composition part 20C subsequently, say it for example, when this sheet material is used as cleaning sheet, will capture for example hair of fibrous foreign matter satisfactorily.

Above-mentioned entanglement coefficient is to represent by the initial slope of the load-deformation curve of testing on the direction perpendicular to fiber orientation, and it is the measured value of expression fibre matting degree.Coefficient is more little, tangles gently more." fiber orientation directions " is meant the direction when maximum load is for maximum in the tensile test, and " stress " is the merchant of tensile load divided by the Unit Weight of sample width that is fixed on tensile test machine jaw place and fiber assembly 1, and " strain " is meant elongation.

Lamilated body 6 is sent on the composition assembly 27 of composition part 20C then.Therebetween, lamilated body 6 is partly pushed by the High-Pressure Water that penetrates in second water jet 28, and wherein lamilated body 6 part that is arranged in depression 27g is depressed, and is projected onto and forms depression 3 (seeing Fig. 1 and 2) among the depression 27g.On the other hand, the part that layered product is positioned on the protruding 27f can not be throwed downwards, becomes projection 2 thus.As a result, whole lamilated body 6 becomes concavo-convex, has a large amount of protruding 2,2 ... and a large amount of depressions 3,3 between the projection 2 ...Projection 2 configuration is decided by that the configuration of composition assembly 27 and entanglement part 20B and composition part 20C mesohigh current are applied to the entanglement energy on the fiber assembly.This entanglement energy is controlled by following condition, the shape of water jet, the arrangement of nozzle (spacing, ranks number and nozzle quantity), hydraulic pressure, linear velocity etc.

Lamilated body 6 with such composition is sent on the feed belt 29 from composition assembly 27 then, carries out drying at this and obtains the Bulkyl sheet 10 shown in Fig. 1 and 2.The continuous Bulkyl sheet 10 that obtains is rolled into or is cut into Len req.The entanglement coefficient of the fiber assembly 1 after the composition is preferably basic identical with composition entanglement coefficient before, and promptly the entanglement coefficient of the fiber assembly 1 after the composition is preferably 0.05-2N.m/g, particularly 0.2-1.2N.m/g.

Among the above-mentioned preparation method, preferably, the mode so that ENERGY E m and Ef satisfy a following general formula at least is applied to respectively on fiber web and the fiber assembly:

200 (kJ/kg)＜Em+Ef＜1250 (kJ/kg), particularly 400＜Em+Ef＜1000

Em/10＜Ef＜2Em/3, particularly Em/4＜Ef＜3Em/5

Wherein, Em is applied on the described fiber web energy that forms fiber assembly by current acupuncture, and Ef is applied on the fiber assembly energy that the part fiber assembly is projected on the composition assembly 27.ENERGY E m and Ef are when above-mentioned scope, and the Bulkyl sheet 10 that obtains has enough bulk structure and intensity, do not have contingent fibre shedding in disadvantageous hole and the preparation process.

ENERGY E m and Ef calculate by following general formula, Wherein, n represents the wide nozzle direction of every 1m top nozzle hole count; ρ represents the density (kg/m of water ³); V represents the flow velocity (m/sec) of nozzle tip water; C represents because the flow coefficient (for water, being 0.592-0.68) of energy consumption; A represents the sectional area of nozzle tip; V represents fibroreticulate process velocity (m/sec); B represents fibroreticulate Unit Weight (g/m ²);

P represents nozzle hydraulic pressure (Pa).

According to above-mentioned method for optimizing, it is low that Bulkyl sheet of the present invention prepares expense, and this is owing to not as the routine techniques that uses latent crimp fiber or heat-shrinkable fibre net, do not need special-purpose heating component.Because the formation of projection does not rely on collapsible fibroreticulate contraction,, can just can form any relief pattern by changing composition assembly 27 simply as long as need therefore no matter be which type of mesh sheets.

The method that another prepares Bulkyl sheet 10 is described below, only describes itself and the concrete difference of said method.Above-mentioned other is described in this and also is suitable for.Be with the difference of said method, current acupuncture causes that fibroreticulate entanglement forms the fiber assembly with above-mentioned entanglement coefficient, the fiber web of this entanglement is superimposed on mesh sheets, difference also is to make one by the bonding lamilated body with fiber assembly and mesh sheets of above-mentioned portion of hot, has so just obtained relief pattern.The projection that this method forms also has high shape retention.Particularly, when the fiber assembly portion of hot of current acupuncture formation is bonding, fiber web and mesh sheets are to finish by heat and pressure that for example cotton ginning applies, the integrated lamilated body that obtains is handled with the High-Pressure Water on the composition assembly, wherein have on the composition assembly and make the part fiber assembly throw concavo-convex or perforate in concavo-convex or the perforate in a large number, form a large amount of projectioies corresponding to depression or perforate, fiber assembly and mesh sheets are tangled and are formed the projection of raising shape retention simultaneously.Preferably, the scope of the ENERGY E m that applies of current acupuncture and Ef is with top identical.

The fiber of forming the fiber assembly of this method use is characterised in that it comprises heat-bondable fiber.Heat-bondable fiber preferably includes core-sheath compound fibre and parallel composite fiber, wherein contain a high-melting-point polymer in the sheath core fiber as sandwich layer, as cortex, bilateral fibre contains high-melting fibre and the low-melting fiber that connects together to fusing point than a low-melting fiber of low at least 10 ℃ of high-melting fibre.The fiber of being made by single a kind of low-melting fiber also is preferred.High-melting-point polymer/low melting point polymer combination of forming composite fibre comprises polypropylene, polyethylene, polyethylene terephthalate/polyethylene and high melting point polyester/low-melting point polyester.The content of heat-bondable fiber is preferably 20-100% weight in the fiber assembly, more preferably 40-80% weight.

Among the above-mentioned preparation method, can use the composition assembly among Fig. 5 (a) and 5 (b), and not use the assembly among Fig. 4 (a)-4 (c).Composition assembly 30 shown in Fig. 5 (a) and 5 (b) comprises the gauze with liquid permeability.Composition assembly 30 comprises a matrix 31 and a large amount of bossings 32 of giving prominence to from matrix 31.Bossing 32 is by making part matrix 31 protrude a side that is formed on matrix 31.This bossing vertically equidistantly is arranged in rows along composition assembly 30.Each row be arranged in make bossing 32 composition assembly 30 vertically on adjacency not each other.Arrange projection 2 and cave in 3 to improve for example ability of chip of thin dust of capture and relative big dust when Bulkyl sheet is used as cleaning sheet for suitable, the distance between the two adjacent bossings 32 is preferably 3-15mm, more preferably 4-10mm.

Bossing 32 has a circular camber line on its plane.Each bossing 32 has identical size and shape, is a mountain type.Bossing 32 is a hollow.In order suitably to arrange projection 2 and depression 3 to improve and to keep the bulkiness of Bulkyl sheet, the high H of bossing 32 (seeing Fig. 5 (b)) is preferably 3-25mm, more preferably 5-15mm.The diameter D of the bossing 32 of test is preferably 2-15mm on matrix 31, more preferably 3-9mm.

In addition, in order to ensure the distance and the enough leavening structures of raising of adjacent two bossings 32, bossing 32 preferably satisfies relational expression P/9≤W≤P/3.In this relational expression, W represents wide (the seeing Fig. 5 (b)) of 2/3 eminence of the bossing 32 of test from matrix 31.

When fiber assembly is when using composition assembly 30 compositions, fiber assembly is to be placed on the composition assembly that forms bossing 32 1 sides.

Now, the present invention is described in more detail reference example.The Unit Weight of the Bulkyl sheet that test obtains.Apparent thickness of the Bulkyl sheet that obtains (thickness under original depth T and the load) and initial apparent specific volume are tested by said method.The entanglement coefficient of the fiber assembly of making and the rate of curving of Bulkyl sheet are tested according to following method.In addition, the Bulkyl sheet that obtains will be assessed the uniformity of itself and ditch seam and capture the ability of big dust according to following method.Test and assessment result are illustrated in the table 1.

1) test of entanglement coefficient

From the fiber coenobium along cut out the wide sample of the long 15mm of 100mm perpendicular to fiber orientation directions.When sample contains mesh sheets, remove this sheet material and only stay fiber assembly.Sample is fixed on the position of the tensile test machine jaw clamping length 50mm of place, and according to pulling out with the speed of 30mm/min perpendicular to fiber orientation directions, tests the relation of pulling force to elongation.The tensile load F of fiber assembly (N) is divided by sample width (m) and Unit Weight W (g/m ²) value defined that obtains is stress S (N.m/g), makes load-deformation curve.

Stress S (N.m/g)=(F/0.015)/W

Only the load-deformation curve of the fiber assembly that forms by the entanglement of forming fiber is a straight line in The initial segment.The slope of this straight line is entanglement coefficient E (N.m/g).

2) test of the rate of curving

From the Bulkyl sheet along cut out the wide sample of the long 15mm of 100mm perpendicular to fiber orientation directions.Specimen is length L a (mm) longitudinally.Then, on the whole area of sample, load 500g.After 5 minutes, remove weight and specimen longitudinal length Lb (mm) once more.When sample contained mesh sheets, load applied after the cutting mesh sheets, carries out testing length Lb (mm) then.

3) with the compliance of ditch seam

The capture rate of earth is tested according to following method in the ditch seam, assesses according to this test rate with the compliance of ditch seam.The acrylic resin board that has spacing and be 6 ditches seams of 3cm is used as the cleaning target.Each ditch seam is the del cross section, the wide 3.0mm of opening, dark 1.5mm.The mixture of 7 kinds of test earth is sprinkling upon in the ditch seam, the long 20cm of each ditch seam, each earth amount is 0.01g (total earth amount is 0.06g).Sample sheets is fixed on the class mop cleaning device Quickle Wiper available from Kao Corp, and twice of wiping on acrylic resin board.The weight of the earth that test is captured by this sheet material, earth capture rate are the earth amounts that are captured to the percentage of the earth amount that sprinkles in the ditch seam.According to this capture rate, the compliance of sheet material is divided into A level (satisfaction), B level (being unsatisfied with) or C level (substantially can not trap dust).

4) performance of the big foreign matter of capture

The chip capture rate is tested according to following method, and captures the ability of big foreign matter according to this ratio assessment.The chip branch of the heavy 0.3g of granular size 1.0-1.4mm is sprinkling upon on the floor of 1m * 1m area.This floor area with the sheet material wiping that is fixed on the Quickle Wipe (Kao Corp), is tested the chip weight that is captured by this sheet material, calculate the chip capture rate thus.According to the chip capture rate that obtains thus, the performance that captures big foreign matter is divided into A level (satisfaction), B level (being unsatisfied with) or C level (can not capture substantially).

Embodiment 1

The blended fiber that to form by polyester fiber in a usual manner combing to make Unit Weight be 29g/m ²Fiber web, wherein contain the polyester fiber of 0.8 dawn of fiber number (0.9 dtex) the long 38mm that mixes with 70: 30 weight mixing ratio and the polyester fiber of 1.45 dawn of fiber number (1.6 dtex) long 51mm in the blended fiber.This fiber web is superimposed at square mesh (width of mesh: 8mm * 8mm, the both sides of polypropylene net netting twine diameter 300 μ m), and the pressure that penetrates in will this superimposed body and function nozzle is that the current acupuncture of 1-5MPa forms a lamilated body, wherein contains the fiber assembly that the entanglement coefficient is 0.5N.m/g.The energy that applies is 295kJ/kg.This lamilated body is sent on the composition assembly of structure shown in Fig. 4 (a)-4 (c), the hydraulic pressure that carries out penetrating thereon from nozzle is that the current of 1-5MPa form relief pattern.Patterned layer zoarium drying in hot-air is obtained the concavo-convex Bulkyl sheet shown in Fig. 1 and 2.The ENERGY E f that applies is 175kJ/kg.The lubricant applying that 90wt% atoleine and 10wt% non-ionic surface active agent (polyethylene oxide alkyl ethers) are formed is on Bulkyl sheet, and consumption is 5% of a sheet material weight.

Embodiment 2

Except fibroreticulate Unit Weight is become 24g/m ², ENERGY E m changes into outside the 427kJ/kg, according to embodiment 1 in identical method make and contain the lamilated body that the entanglement coefficient is the fiber assembly of 0.79N.m/g.This lamilated body is sent on the different composition assembly with structure shown in Figure 4 of configuration and embodiment 1, uses the hydraulic pressure that penetrates in the nozzle to form relief pattern thereon as the current of 1-5MPa.Obtain having Bulkyl sheet concavo-convex shown in Fig. 1 and 2 with this patterned layer zoarium is dry in hot-air, according to the mode application of lubricating identical with embodiment 1.The ENERGY E f that uses is 252kJ/kg.

The comparative example 1

With fiber web (0.9 dtex 38mm/1.7 dtex 51mm=70wt%/30wt%, Unit Weight 24/m ²) superimposed respectively on the upper and lower surface of mesh sheets, identical among this mesh sheets and the embodiment 1 obtains this fibroreticulate fiber assembly by current acupuncture then, forms lamilated body.The entanglement coefficient of this fiber assembly is 0.8N.m/g.According to embodiment 1 in identical method application of lubricating on this lamilated body.In this explanation, this lamilated body does not have composition.

The comparative example 2

Use the Swiffer that a kind of commercially available discardable cleaning sheet Procter andGamble that has net-like pattern provides (Lot, 9345CA1221040206).

Table 1

	Embodiment		The comparative example
	Embodiment		The comparative example		????1	????2	????1	????2
	Unit Weight (the g/m of fiber assembly ²)	??58.0	????48.0	????48.0	????1	????2	????1	????2	????52.4
Apparent thickness T (mm)	Unit Weight (the g/m of fiber assembly ²)	??58.0	????48.0	????48.0	??3.2	????1.5	????0.9	????1.1	????52.4
Apparent thickness T (mm)	Apparent specific volume amasss (cm ³/g)	??55.2	????31.3	????18.8	??3.2	????1.5	????0.9	????1.1	????21.0
Apparent thickness under the load (mm)	Apparent specific volume amasss (cm ³/g)	??55.2	????31.3	????18.8	??2.5	????1.1	????0.7	????0.8	????21.0
Apparent thickness under the load (mm)	The rate of curving	??8.5	????3.7	????1.2	??2.5	????1.1	????0.7	????0.8	????1.0
Uniformity earth capture rate (%) to the ditch seam	The rate of curving	??8.5	????3.7	????1.2	????A ????70	????A ????65	????C ????10	????C ????23	????1.0
Uniformity earth capture rate (%) to the ditch seam	Big foreign matter captures performance chip capture rate (%)	????A ????95	????A ????90	????B ????70	????A ????70	????A ????65	????C ????10	????C ????23	????B ????70

Can clearly be seen that from table 1 Bulkyl sheet of the present invention is very consistent with the ditch seam, and can capture for example chip of big foreign matter satisfactorily.Bulkyl sheet among the comparative example has poor uniformity to the ditch sewer, and has the ability of the poor big foreign matter of capture.

Bulkyl sheet of the present invention does not limit shape, density and the arrangement of projection.In the said method, fiber web is superimposed two sides in mesh sheets, and it also can only superimposed one side in mesh sheets.

From some purposes, Bulkyl sheet of the present invention always need not use mesh sheets 4 in above-mentioned Bulkyl sheet 10.

The configuration of mesh sheets is not particularly limited the mesh sheets 4 for the square mesh that uses in the above-mentioned embodiment, anyly as carrier fiber web can tangled shape all-in-one-piece mesh sheets can be used.

In the above-mentioned embodiment, fiber web is when a side is carried out current acupuncture, and current acupuncture is all carried out in fibroreticulate both sides.At this moment, ENERGY E m is the summation that is applied to each side energy.

Operable composition assembly can contain the straight line of the square mesh of woven formation rather than the straight line 27a that is arranged in parallel in the inventive method.The straight line 27a that is arranged in parallel can replace with the plate that has a large amount of square meshes, and line 27b twines around its spiral.In addition, the perforated panel that has a large amount of circular opens also can be used as the composition assembly.Distance between this plate horizontal and vertical two adjacent openings is corresponding to the distance between the horizontal and vertical adjacent protrusion of gained Bulkyl sheet.

Industrial applicibility

Bulkyl sheet of the present invention has a large amount of projections, and is soft, and sense of touch is comfortable, therefore is fit to do cleaning sheet and hygienic articles for example mouth mask and gauze. The Bulkyl sheet expense that the inventive method obtains is low.

Particularly when as cleaning sheet, the dust cleaning performance of Bulkyl sheet of the present invention is very excellent, can capture dirt for example dust or other small foreign body in the cleaning surface composition fiber slit, also can collect and be present in surperficial recess and be difficult to be captured in relatively large foreign matter disintegrating slag for example in the fiber. In addition, cleaning sheet and floor ditch seam or furniture, electrical apparatus product etc. not plane surface comply with consistent, to remove dirt or the chip in the plane surface not. Cleaning sheet with suitable thickness is convenient to be used in the wiping operation.

Claims

1, a kind of Bulkyl sheet that contains the fiber assembly that forms by the current needled web, described Bulkyl sheet have in a large number by described fiber assembly constitute concavo-convex, described concavo-convex be to rearrange it by the described fiber assembly of current acupuncture to form fiber and the multiple bend mode that it carries out is formed along the fiber assembly thickness direction, and describedly concavo-convexly self have shape retention.

2, a kind of Bulkyl sheet that contains the fiber assembly that forms by current needled web and mesh sheets, described Bulkyl sheet have in a large number by described fiber assembly constitute concavo-convex, the composition fiber of the described fiber assembly that tangles each other by described current acupuncture further tangles with described mesh sheets and/or heat bonding forms one thus, described concavo-convex be to rearrange it by the described fiber assembly of current acupuncture to form fiber and the multiple bend mode that it carries out is formed along the fiber assembly thickness direction, and describedly concavo-convexly self have shape retention.

3, according to the Bulkyl sheet of claim 1, its apparent thickness is 1-5mm, and apparent volume is 23-100cm ³/ g.

4, according to the Bulkyl sheet of claim 1, its elongation longitudinally of testing under condition 5N/30mm is 5% or littler.

5, according to the Bulkyl sheet of claim 1, the fiber number that wherein said fiber assembly contains is that the content of 5 dtexs or littler fiber is 50% weight or more, and Unit Weight is 30-100g/m ²

6, a kind of preparation comprises the steps: according to the method for the Bulkyl sheet of claim 1

200(kJ/kg)＜Em+Ef＜1250(kJ/kg)

Em/10＜Ef＜2Em/3

7, according to the method for claim 6, wherein said fibroreticulate composition fiber tangles each other by current acupuncture, and the entanglement coefficient of the fiber assembly of Xing Chenging is 0.05-2.0N.m/g thus.

8, a kind of preparation comprises the steps: according to the method for the Bulkyl sheet of claim 2

200(kJ/kg)＜Em+Ef＜1250(kJ/kg)

Em/10＜Ef＜2Em/3

9, according to the Bulkyl sheet of claim 2, wherein said Bulkyl sheet does not carry out thermal contraction to described mesh sheets, and the percent thermal shrinkage that perhaps carries out the described mesh sheets of test in 3 minutes under 140 ℃ is 3% or littler.

10, according to the Bulkyl sheet of claim 1, the fracture strength of the wide sample of its 30mm is at least 5N.